Fe-based nanocrystalline alloy and electronic component using the same

Abstract

An Fe-based nanocrystalline alloy is represented by Composition Formula, (Fe (1-a) M 1 a) 100-b-c-d-e-g M 2 b B c P d Cu e M 3 g , where M 1 is at least one element selected from the group consisting of Co and Ni, M 2 is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, and Mn, M 3 is at least two elements selected from the group consisting of C, Si, Al, Ga, and Ge but necessarily includes C, and 0≤a≤0.5, 1.5<b≤3, 10≤c≤13, 0<d≤4, 0<e≤1.5, and 8.5≤g≤12.

What is claimed is: 
     
       1. An electronic component comprising:
 a coil part; and 
 an encapsulant encapsulating the coil part and containing an insulator and magnetic particles dispersed in the insulator, 
 wherein the magnetic particles contain an Fe-based alloy represented by composition formula, (Fe (1-a) M 1 a) 100-b-c-d-e-g M 2   b B c P d Cu e M 3   g , where M 1  is at least one element selected from the group consisting of Co and Ni, M 2  includes NB, M 3  includes C and Si, and 0≤a≤0.5, 1.5<b≤3, 10c≤13, 0≤d≤4, 0<e≤1.5, and 8.5≤g≤12, and a, b, c, d, e and g are atom ratios, 
 wherein a ratio of a weight of C to a sum of weights of Fe and C is within a range from 0.1% or more to 0.7% or less, 
 wherein an absolute amount of C is within a range of 0.1 to 0.6 wt %, and 
 wherein the magnetic particles have a size distribution with a D 50  of 20 um or more. 
 
     
     
       2. The electronic component of  claim 1 , wherein a parent phase of the Fe-based alloy has an amorphous single phase structure. 
     
     
       3. The electronic component of  claim 1 , wherein an average size of a crystalline grain after heat treatment is 50 nm or less. 
     
     
       4. The electronic component of  claim 1 , wherein a saturation magnetic flux density of the Fe-based alloy is 1.4 T or more. 
     
     
       5. The electronic component of  claim 1 , wherein a ratio of a weight of C to a sum of weights of Fe and C is within a range from 0.3% or more to 0.7% or less. 
     
     
       6. The electronic component of  claim 1 , wherein a ratio of a weight of C to a sum of weights of Fe and C is within a range from 0.4% or more to 0.7% or less.